Sensor Based Fixture Design and Verification

The objectives of Sensor Based Fixture Design and Verification (SFDV) research are to provide the means for detecting contact failure of the workpiece with fixture locators and for preventing incorrect loading of the workpiece in a fixture. The fixtures that involve complex free-form surfaces especially in the aerospace industries face problems caused by the contact failure of the workpiece with locators. In batch and mass production defects often occur due to incorrect loading of the workpiece in a fixture by an operator due to fatigue or inadvertence. The current fixturing research is focussed on improving the fixture quality and other aspects and do not address these issues. This research is focussed on three areas, to generate algorithms for automatically foolproofing the fixtures, to build locators with embedded sensors that could be used to verify the contact and foolproof the existing fixtures, and to design and experimentally validate fixtures for free-form surfaces with sensors to verify the location. In foolproofing, workpieces were classified into different categories to identify the existence of a solution and the geometry was simplified and used to search for a solution based on symmetry/asymmetry to discover a foolproofing location. The algorithms were implemented in a CAD software and the solutions were verified in 3D space. The locators with inbuilt sensors were designed for foolproofing and location verification purposes and the sensors were used in case studies to establish credibility. A sensor based fixture design method is created for the part location of free-form surfaces using fiber optic sensors. An experimental fixture with sensors incorporated in the locators was used to determine the effects of surface curvature on the sensitivity of the sensors. A new theory on best locations for the sensor based locators by utilizing surface curvature is proposed based on the experimental results. The SFDV implementation may help realize the dream for any manufacturing sys­tem aspiring to move beyond the six sigma levels of quality and achieve zero defects

A Genetic Algorithm for Fixture Synthesis and Variation

Concepts in manufacturing such as CIMS (Computer Integrated Manufacturing Systems), JIT (Just In Time), Lean Production, Virtual Manufacturing, and Flexible Fixturing have been proposed to meet the fundamental requirements of manufacturing - decrease the cost and satisfy the needs of customers. Fast fixture generation and fixture reusability are essential in the current manufacturing environment. The dissertation focuses on the models, methods, and algorithms for fixture synthesis and variation that satisfy the functional requirements specified by on-site industrial engineers. With the reusability of a fixture base combined with variation of other fixture components, fixture configuration can be rapidly adapted and accommodated to the new workpiece. The dissertation presents methods and algorithms for fixture base synthesis, which directly result in fixture reusability. Optimization functions are derived based on engineering requirements due to the mass production nature of automotive parts. Specific optimization algorithms are developed and their complexities, compared to other alternatives, are comprehensively evaluated according to different optimization functions. The fixture variation and reusability provide an engineering tool to rapidly generate and validate fixtures in production planning stage. It applies scientific reasoning methodology in combination with best knowledge of fixture designs, which heavily relies on designers\u27 manufacturing knowledge and experience. It also provides means to bridge the gap between CAD and CAM integration and therefore reduces the new product and production development cycle time and cost while maintaining the quality of fixtures

Active fixturing: literature review and future research directions

Fixtures are used to fixate, position and support workpieces and represent a crucial tool in manufacturing. Their performance determines the result of the whole manufacturing process of a product. There is a vast amount of research done on automatic fixture layout synthesis and optimisation and fixture design verification. Most of this work considers fixture mechanics to be static and the fixture elements to be passive. However, a new generation of fixtures has emerged that has actuated fixture elements for active control of the part–fixture system during manufacturing operations to increase the end product quality. This paper analyses the latest studies in the field of active fixture design and its relationship with flexible and reconfigurable fixturing systems. First, a brief introduction is given on the importance of research of fixturing systems. Secondly, the basics of workholding and fixture design are visited, after which the state-of-the-art in active fixturing and related concepts is presented. Fourthly, part–fixture dynamics and design strategies which take these into account are discussed. Fifthly, the control strategies used in active fixturing systems are examined. Finally, some final conclusions and prospective future research directions are presented

EFFICIENCY OF FLEXIBLE FIXTURES: DESIGN AND CONTROL

The manufacturing industries have been using flexible production technologies to meet the demand for customisation. As a part of production, fixtures have remained limited to dedicated technologies, even though numerous flexible fixtures have been studied and proposed by both academia and industry. The integration of flexible fixtures has shown that such efforts did not yield the anticipated performance and resulted in inefficiencies of cost and time. The fundamental formulation of this thesis addresses this issue and aims to increase the efficiency of flexible fixtures.To realise this aim, the research in this thesis poses three research questions. The first research question investigates the efficiency description of flexible fixtures in terms of the criteria. Relative to this, the second research question investigates the use of efficiency metrics to integrate efficiency criteria into a design procedure. Once the efficiency and design aspects have been established, the third research question investigates the active control of flexible fixtures to increase their efficiency. The results of this thesis derive from the outcome of seven studies investigating the automotive and aerospace industries. The results that answer the first research question use five criteria to establish the efficiency of flexible fixtures. These are: fundamental, flexibility, cost, time and quality. By incorporating design characteristics in respect of production system paradigms, each criterion is elaborated upon using relevant sub-criteria and metrics. Moreover, a comparative design procedure is presented for the second research question and comprising four stages (including mechanical, control and software aspects). Initially, the design procedure proposes conceptual design and verification stages to determine the most promising flexible fixture for a target production system. By executing detailed design and verification, the design procedure enables a fixture designer to finalise the flexible fixture and determine its efficiency. Furthermore, a novel parallel kinematics machine is presented to demonstrate the applicability of the design procedure’s analytical steps and illustrate how appropriate kinematic structures can facilitate the efficiency-orientated design of flexible fixtures.Based on the correlation established by the controller software’s design procedure, the active control of flexible fixtures directly affects the quality criterion of flexible fixture efficiency. This provides the answer to the third research question, on general control strategies for active control of flexible fixtures. The introduction of a system model and manipulator dynamics proposes force and position control strategies. It is shown that any flexible fixture using a kinematic class can be controlled, to regulate the force and position of a workpiece and ensure that process nominals are preserved. Moreover, using both direct and indirect force control strategies, a flexible fixture’s role in active control can be expanded into a system of actively controlled fixtures that are useful in various processes. Finally, a position controller is presented which has the capacity to regulate both periodic and non-periodic signals. This controller uses an additional feedforward scheme (based on the Hilbert transform) in parallel with a feedback mechanism. Thus, the position controller enables flexible fixtures to regulate the position of a workpiece in respect of any kind of disturbance

Mobility of bodies in contact. II. How forces are generated bycurvature effects

For part I, see ibid., p.696-708. The paper considers how forces are produced by compliance and surface curvature effects in systems where an object a is kinematically immobilized to second-order by finger bodies Al,...,Ak. A class of configuration-space based elastic deformation models is introduced. Using these elastic deformation models, it is shown that any object which is kinematically immobilized to first or second-order is also dynamically locally asymptotically stable with respect to perturbations. Moreover, it is shown that for preloaded grasps kinematic immobility implies that the stiffness matrix of the grasp is positive definite. The stability result provides physical justification for using second-order effects for purposes of immobilization in practical applications. Simulations illustrate the concepts

Robotic disassembly of electronic components to support end‐of‐life recycling of electric vehicles

This thesis reports on the research undertaken to analyse the factors affecting End-of-Life (EoL) recycling of future Electric Vehicles (EVs). The principle objective of the research is to generate an understanding of challenges and opportunities for the development and implementation of an automated robotic disassembly approach to aid with EoL management of electrical and electronic components within EVs. The research contributions are considered in three main parts. The first part contains a review of advancement in the development of automotive technology, and in particular the alternative fuel vehicles. A review of existing industrial recycling technologies and processes has been conducted which highlighted a number of key challenges in the adoption of current recycling technologies for EVs. The review concludes that there is a need to develop novel recycling technologies and processes to deal with the increased part complexity and material mixture in such vehicles. In this context, the second part of the research details a framework for EoL management of EV components. This framework presents a comprehensive automated robotic disassembly approach in which three specific steps are defined, namely manual disassembly to develop an understanding of product design, initial automated disassembly to test process capability, and optimisation and validation to improve repeatability and efficiency of the robotic disassembly operations. The framework also includes the development of a multi-criteria decision-making tool that assesses the environmental, technological and economic benefits of such robotic disassembly approach. The applicability of the research concepts has been demonstrated via three case studies. The results have highlighted the applicability of the automated robotic disassembly approach in a variety of scenarios of different design complexity and recovery rate. The results indicate that the adoption of this robotic disassembly enhances the pre-concentration of Strategically Important Materials (SIMs) and leads to minimisation of environmental impacts and increased material recovery value

Fixture-Based Design Similarity Measures for Variant Fixture Planning

One of the important activities in process planning is the design of fixtures to position, locate and secure the workpiece during operations such as machining, assembly and inspection. The proposed approach for variant fixture planning is an essential part of a hybrid process planning methodology.The aim is to retrieve, for a new product design, a useful fixture from a given set of existing designs and their fixtures. Thus, the variant approach exploits this existing knowledge. However, since calculating each fixture's feasibility and then determining the necessary modifications for infeasible fixtures would require too much effort, the approach searches quickly for the most promising fixtures based on a surrogate design similarity measure. Then, it evaluates the definitive usefulness metric for those promising fixtures and identifies the best one for the new design

A frame for a computer aided inspection planning system

Coordinate Measuring Machine (CMM) inspection planning is an activity performed by well-trained operators, but different measurement techniques, using the same data analysis algorithms yield in different measurement results. This is a well-recognized source of uncertainty in coordinate measurement. A CMM, provided with an automatic inspection planning (CAIP) system, permits to implement more accurate and efficient operating procedures and to fit higher quality assurance standards and tighter production timings. In this paper we present a frame of a CAIP system, able to deal with almost all the decisional stages of CMM inspection. Moreover, original approaches have been developed and presented in inspection feature selection, part set -up, probe configuration, and path planning